Flooring System of Sandwich-Like Floor Elements Having a Core of Insulating Material

ABSTRACT

A flooring system comprises a preformed composite panel having a first sheet ( 2 ), a second sheet ( 3 ) and a core of insulating material between the first and second sheets ( 2, 3 ). In one case the sheet ( 2 ) is a generally flat top sheet and the sheet ( 3 ) is a profiled bottom sheet. A floor such as a wood effect floor ( 5 ) is laid over the flat top sheet ( 2 ). An acoustic barrier layer  6  is located between the floor ( 5 ) and the sheet ( 2 ). The profiling of the sheet ( 3 ) defines channels ( 7 ) for location of service ducts/conduits ( 11 ). A planar facing ( 8 ) is applied over the profiled sheet, bridging the channels ( 7 ).

INTRODUCTION

The invention relates to a floor system for intermediate floors and ground floors in for example, domestic houses or multi-story buildings

In one current approach a formwork is used to enable installation of a poured in place concrete floor. When the concrete is set the formwork is removed. However, the disadvantages of such an approach include difficulties in locating services, installing insulation and span is limited necessitating load bearing support walls.

STATEMENTS OF INVENTION

According to the invention there is provided a flooring system comprising:

-   -   a composite panel of the type comprising a first sheet and a         second sheet and an insulating core between the first and second         sheets; and     -   a floor applied over one of the skins.

In one embodiment the floor is preformed and laid on the panel in situ. The floor may be a wood or wood-effect floor. In one embodiment an acoustic barrier layer is provided between the panel and the floor.

In one preferred aspect at least one of the skins is profiled to define a plurality of channels extending longitudinally along the length of the panel. In one embodiment the lowermost in use of the skins is profiled.

In one embodiment a generally planar facing is applied over the profiled skin, bridging the channels. Preferably, support battens are provided between the profiled skin and the facing. At least some of the battens preferably extend transversely across the panel, bridging the channels.

The facing may be of plasterboard or the like.

In one embodiment the flooring system comprises a service duct or conduit located in the channel.

The formations may be of generally trapezoidal shape comprising a generally flat base and side walls which extend from and diverge outwardly from the base.

In one embodiment the side walls of the trapezoidal formations have stepped side-walls. The sheet having the trapezoidal formations may have transversely extending reinforcing ribs.

In one embodiment the first sheet has a first overlap portion on one side and a second overlap portion on the opposite side, the first overlap portion being substantially free of insulating core, the side edge of the insulating core at the first overlap portion having a first inclined wedge face and the side edge of the insulating core at the second overlap portion having a second inclined wedge face which is oppositely directed to the first inclined wedge face at the first overlap portion, the overlap portions and the wedge faces of the insulating core of adjacent like panels being interengageable on assembly.

The first sheet overlap portions may be defined by part trapezoidal portions.

In one embodiment the second sheet has a second sheet first overlap portion on one side and a second sheet second overlap portion on the opposite side.

The second sheet may have an outer male projecting part and an inner recess part on one side, and a corresponding outer recess part and projecting inner male part respectively on the opposite side of the panel.

In another case the floor is formed in-situ, for example from a cementitious material.

In one embodiment a floor covering is applied over the floor.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be more clearly understood from the following description thereof, given by way of example only, with reference to the accompanying drawings, in which:—

FIG. 1 is a transverse cross-sectional view of a flooring system according to the invention;

FIG. 2 is a longitudinal cross sectional view of the flooring system of FIG. 1;

FIG. 3 is a cross sectional view in the direction of the arrow A in FIG. 2;

FIG. 4 is an enlarged view of a joint detail of the flooring system;

FIG. 5 is an enlarged view of a panel joint detail of the flooring system of FIG. 1;

FIG. 6 is a perspective view of one sheet of a panel used in the flooring system;

FIG. 7 is a plan view of the panel sheet of FIG. 6;

FIGS. 8( a) to 8(c) are cross-sectional views of various alternative panels of the flooring system;

FIG. 9 is a transverse cross-sectional view of another flooring system according to the invention;

FIG. 10 is a transverse cross-sectional view of another flooring system according to the invention;

FIG. 11 is a cross sectional view of a detail of the flooring system of FIG. 10;

FIG. 12 is a longitudinal cross sectional view of the flooring system of FIG. 10; and

FIG. 13 is a cross sectional view in the direction of the arrow B in FIG. 12.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring to the drawings and initially to FIGS. 1 to 7 thereof, there is illustrated a flooring system according to the invention comprising a preformed composite panel of the type having a first sheet 2, a second sheet 3 and a core 4 of insulating material between the first and second sheets 2, 3 and a floor 5. The sheets 2, 3 are typically of steel material and the core 4 is of polyurethane or polyisocyanurate foam material which fills the space between the sheets 2, 3. In this case one of the sheets is a generally flat top sheet 2 and the other (3) of the sheets is a profiled bottom sheet 3. An underlay 6 is generally provided between the floor 5 and the sheet 2. The underlay 6 may be an acoustic barrier layer or may include such an acoustic barrier layer.

The sheet 3 is profiled to define a plurality of channels 7 extending longitudinally along the length of the panel. In the case of an intermediate or upper floor a generally planar facing such as plasterboard 8, or plywood or the like is applied over the profiled sheet 3, bridging the channels 7. For ease of fitting, generally support battens 9 are mounted to and extend transversely of the profiled sheet, bridging the channels 7. Any suitable fixing means such as fixing clips may then be used to fix the facing 8 to the battens 9.

The channels 7 define passageways for services which may be a services duct or conduit 11 for electrical, plumbing, air conditioning/ventilation or other services. Services 11 are installed into the channels 7 which provides an unobstructed and defined passageway for the services. The form of the channels 7 ensures accurate location and alignment of any services accommodated therein. The services ducts/conduits are readily mounted in the channels 7 after the floor is installed. They can also be readily accessed for service, maintenance, replacement or re-mounting by simply removing the facing panels in this case.

In use, the panels 1 are supported between walls 20, 21, in this case an external wall 20 and an internal wall 21. The panels 1 have a large span of typically at least 5 meters, thus the panels can be used to provide constructional floors over a large expanse without the requirement for intermediate supports. This is very advantageous as it facilitates flexibility in the living space. A large unobstructed area is provided which can then be readily subdivided to suit a particular requirement or design by using, for example, partitioning. Such partitioning (because it does not have a structural support function) can be readily dismantled, re-assembled or re-built to suit a new design or specification for the living space. The fact that the main service ducts are hidden and located above the space again facilitates such re-arrangement.

Referring to FIGS. 5 to 8, the preformed composite panels 1 used in the flooring system of the invention are shown in more detail. The profiled sheet 3 has a plurality of generally trapezoidal formations 30 each having a generally flat base part 31 and a pair of upwardly extending and diverging side walls 32. Stepped back intermediate portions 33 are located between the trapezoidal formations 30. For enhanced structural strength the side walls 32 of the trapezoidal formations are of stepped form. Transversely extending reinforcing ribs 35 are provided in the intermediate portions 33 to again enhance structural performance.

The profiled sheet 3 has a first side overlap portion 40 on one side and a second side overlap portion 41 on the opposite side. The first overlap portion 40 is substantially free of insulating core 4 and the side edge of the insulating core at the first overlap portion has a first inclined wedge face 43. At the second side overlap portion 41 the side edge of the insulating core has a second inclined wedge face 44 which is oppositely directed to the first inclined wedge face 43 so that the wedge faces 43, 44 of adjacent like panels are interengagable on assembly.

The generally flat sheet 2 may have a first overlap portion 50 on one side and a second overlap portion 51 on the opposite side. The first overlap portion 50 comprises an outer male projecting part 52 and an inner recess part 53. The second overlap portion 51 comprises an outer recess part 54 and an inner male projecting part 55 which are interengagable with the outer male projection 52 and the inner recess part 53 of an adjacent like panel, on assembly.

Various alternative constructions of composite panels to suit various requirements used in flooring systems of the invention are illustrated in FIGS. 8( a) to 8(c). In one case (FIG. 8( a)) there is no engagement features formed in the sheet 2.

Referring to FIG. 9 there is illustrated an alternative flooring system of the invention. Parts similar to those of the flooring system described above are assigned the same reference numerals. In this case, a cementitious or other suitable flowable material is applied over the top sheet 2 and a covering 61 may be applied over the material 60, when set. To facilitate bonding key features may be formed in or provided on the top sheet 2. The cementitious layer 60 may have suitable reinforcements.

In another arrangement as illustrated in FIGS. 10 to 13 the panels are laid so that the profiled sheet 3 is uppermost and the generally flat sheet 2 is lowermost. A top layer 10 of a flowable material such as concrete is provided to which a covering 71 may be applied.

The flooring system of the invention has the advantage of providing a floor of excellent structural integrity that includes insulation, and the facility to accommodate services. This eliminates the need for the user/installer to separately obtain and to lay insulation. In addition the floor system of the invention has the advantages of improved ease of installation.

The flooring system of the invention has the further advantages that it provides an integral passageway for services. It facilitates ease of location and installation of services and provides means for alignment of the services.

The engagement features of the panels facilitate a high quality joint having a high levels of insulation, fire performance. The arrangement of the wedge faces of the insulating core at the joint and overlap and the other features described above also provide for high mechanical strength.

The invention is not limited to the embodiments hereinbefore described which may be varied in construction and detail. 

1-22. (canceled)
 23. A flooring system comprising: a composite panel of the type comprising a first sheet and a second sheet and an insulating core between the first and second sheets; and a floor applied over one of the skins.
 24. The flooring system as claimed in claim 23 wherein the floor is preformed and laid on the panel in situ.
 25. The flooring system as claimed in claim 24 wherein the floor is a wood or wood-effect floor.
 26. The flooring system as claimed in claim 24 comprising an acoustic barrier layer between the panel and the floor.
 27. The flooring system as claimed in claim 23 wherein at least one of the skins is profiled to define a plurality of channels extending longitudinally along the length of the panel.
 28. The flooring system as claimed in claim 27 wherein the lowermost in use of the skins is profiled.
 29. The flooring system as claimed in claim 28 comprising a generally planar facing which is applied over the profiled skin, bridging the channels.
 30. The flooring system as claimed in claim 29 wherein support battens are provided between the profiled skin and the facing.
 31. The flooring system as claimed in claim 30 wherein at least some of the battens extend transversely across the panel, bridging the channels.
 32. The flooring system as claimed in claim 29 wherein the facing is of plasterboard.
 33. The flooring system as claimed in claim 27 wherein the flooring system comprises a service duct or conduit located in the channel.
 34. The flooring system as claimed in claim 27 wherein the formations are of generally trapezoidal shape comprising a generally flat base and side walls which extend from and diverge outwardly from the base.
 35. The flooring system as claimed in claim 34 wherein the side walls of the trapezoidal formations have stepped side-walls.
 36. The flooring system as claimed in claim 34 wherein the sheet having the trapezoidal formations has transversely extending reinforcing ribs.
 37. The flooring system as claimed in claim 23 wherein the first sheet has a first overlap portion on one side and a second overlap portion on the opposite side, the first overlap portion being substantially free of insulating core, the side edge of the insulating core at the first overlap portion having a first inclined wedge face and the side edge of the insulating core at the second overlap portion having a second inclined wedge face which is oppositely directed to the first inclined wedge face at the first overlap portion, the overlap portions and the wedge faces of the insulating core of adjacent like panels being interengageable on assembly.
 38. The flooring system as claimed in claim 37 wherein the first sheet overlap portions are defined by part trapezoidal portions.
 39. The flooring system as claimed in claim 23 wherein the second sheet has a second sheet first overlap portion on one side and a second sheet second overlap portion on the opposite side.
 40. The flooring system as claimed in claim 39 wherein the second sheet has an outer male projecting part and an inner recess part on one side, and a corresponding outer recess part and projecting inner male part respectively on the opposite side of the panel.
 41. The flooring system as claimed in claim 23 wherein the floor is formed in-situ.
 42. The flooring system as claimed in claim 41 wherein the floor is of a cementitious material. 